Clopay 84A Installation guide

Type
Installation guide
P/N 0137391 REV 00/
Glass, Plexiglass, Stained Look, Leaded
Look, Brilliance, and Studio Series Windows
Cleaning and Care Instructions
Clean with a mild solution of a dishwashing detergent
and a soft cloth. After cleaning, rinse thoroughly. DO
NOT use any ammoniated, abrasive, or solvent-based
cleaners of any kind.
Studio Series Windows Only:
Use a good grade of automotive paste wax and buff with a
soft cloth. Windows should be cleaned and waxed at least
once annually or more often based on the atmospheric
conditions where installed.
Caution: Use care when handling decorative windows to
avoid scraping or scratching the surface.
NOTE: Minor scratches or scuffs are not considered
1400 West Market Street
defects and will not be covered under the window warranty.
Troy, OH 45373 USA
0409
999
Painting preparation: Clean surface first with a diluted
solution of Trisodium Phosphate. The recommended
concentration is 1/3 cup of powder to 1-1/2 to 2 gallons of
water. A cleaning pad (3M Synthetic steel wool GRAY not
green) should be used saturated with this cleaning solution.
Rub with even pressure to lightly scuff the surface while ap-
plying the cleaning solution over all surfaces to be painted.
A final wipe and rinse with clean water and sponge should
be done to remove any loose material. Change water often
to ensure clean rinse and allow to dry. Pre test your paint
on a small area (see paragraph Paint below). If the paint
shows signs of poor adherence, (tape test below) there may
be a problem with the paint or the surface preparation. DO
NOT PROCEED! A new paint or further preparation of the
surface is called for.
Alternate cleaning compounds: Areas of the country that
do not carry Trisodium Phosphate can use a biodegradable
cleaner with the cleaning pad above. Follow above
directions to rinse completely and pre test paint.
Painting: Your steel garage door can be painted with a
high quality 100% acrylic latex (flat, satin, or semigloss)
exterior grade paint. Before painting the door it must be free
of dirt, oil, caulk, waxes and mildew.
Do not use any type of oil based paint or Alkyd modified
acrylic latex paint. These paints will void the warranty of
your door.
C32-R0 -
1
15 yrs.
004 9
2009
48, 48B, 84A, 94, 4800, 4801, 4803, HDB4, T40F,
52, 52S, 54, 54S, 55, 55HB, 55S, 76V, 183, 186,
187, 190, 1000, 1001, 1100, 1500, 5200, 5201,
5203, 5500, 5501, 5503, HDS, HDSL, HDSF, T51S,
42, 42B, 46, 46B, 73, 75, 75L, 76, 4200, 4201,
4203, HDB, HDBF, HDBL, T50L, T50S, TM50S
T51F, T51L, T52L, T52S
T40L, TM40S, T41F, T41L, T41S, T42F, T42L, T42S
G01-R03-0906
Introduction and Opening Preparation
STEP 1 – Things to Know Before You Begin ....................................................................................................3
STEP 2 – Read Safety Information ..................................................................................................................4
STEP 3 – Check Headroom, Backroom, Sideroom ..........................................................................................5
STEP 4 – Removing the Existing Door Springs ...............................................................................................6
STEP 5 – Removing Door Sections and Track .................................................................................................7
STEP 6 – Preparing the Opening .....................................................................................................................7
Preparing the New Door
Typical Garage Door Installation Illustration .....................................................................................................8
Hardware Components ....................................................................................................................................9
Installing the New Door
STEP 7 – Preparing Bottom Section ..............................................................................................................10
STEP 8 – Lift Handle Attachment............. ......................................................................................................12
STEP 9 – Installing Door Sections.............. ...................................................................................................13
STEP 10 – Reinforcing the Top Section for Opener Attachment ....................................................................14
STEP 11 – Assembling and Installing Track ...................................................................................................15
STEP 12 – Lock Installation (if included).................. ......................................................................................17
STEP 13 – Pull Rope.......... ............................................................................................................................17
STEP 14 – Spring Installation....... ..................................................................................................................17
STEP 15 – Attaching an Automatic Opener ....................................................................................................18
Maintenance/Adjustments/Options
Painting and Windows ....................................................................................................................................19
Maintenance ...................................................................................................................................................20
Checking and Adjusting the Door ...................................................................................................................20
Replacement Parts .........................................................................................................................................20
Table of Contents
STEP 1 – Things to Know Before You Begin
Read the instructions completely before starting the installation
of the door. Becoming familiar with the components before
assembling the door will reduce the installation time.
Be sure all hardware components for your new door are included
before removing existing door (see pages 8,9). If your door is
missing any parts, call the toll-free Consumer Services number
listed on the front of this manual.
Allow enough time to do the work; removing an existing door will
take approximately 1-3 hours.
An assistant may be required for lifting the unsprung door. It can
weigh from 100 to 500 pounds.
A typical installation takes between 9 and 12 hours to complete.
Keep in mind when planning the installation that the garage
will be open and unsecured when disassembling the old and
assembling the new door.
If the garage door is the only opening in the structure make sure
everything you need is inside. You will have no way of leaving the
garage until the track is assembled and installed. This will take
approximately 5 hours.
To avoid damage to the door, you must reinforce the top section
of the door in order to provide a strengthened mounting point for
attachment of an automatic opener (see page 14).
Low Headroom doors require special instructions. Options for
doors with low headroom can be found on page 5. Purchase
of additional hardware may be required. Check headroom
requirements in the chart on page 5 before beginning.
To avoid installation problems which could result in personal injury
or property damage, never reuse old track or hardware.
Doors installed in high windload regions (Florida and other high
wind prone areas) may require additional reinforcement beyond
what is detailed in these instructions. Please refer to supplemental
instructions for these areas.
Express warranties apply only to doors installed using original,
factory-supplied sections, parts, and hardware installed in strict
accordance with these instructions.
Tools Needed
“C” Clamps or Locking Pliers
• Hammer
• Screwdriver
• Tape Measure
• Level
Socket wrench kit
• Pliers
Drill, 1/4", 3/16", & 3/8" drill bits, and 7/16" socket bit
• Step ladder
Saw horses (with carpet or other soft material on top surface;
2 needed for doors up to and includiing 9'0" wide, 3 needed for
doors over 9'0" wide) or other supports for placing section on
while assembling
• Hacksaw
• Wood Saw
• T-Square
Additional tools may be required; see the Spring Supplement for
more information.
Additional Material Required
Light household oil
1-1/4" x 1-1/4" Minimum punched angle
- 13 ga. (3/32") minimum thickness for Operator Reinforcement
(see page 14)
- 16 ga. (1/16") minimum thickness for rear track hangers on
doors weighing up to 300 lbs. that use torsion springs, or doors
weighing up to 150 lbs. that use extension springs. If your door
exceeds these weight limitations, or if you do not know the weight
of your door, 13 ga. angle should be used. (See page 16)
Eight 3/8" x 1" bolts and nuts for rear track hangers
Six 5/16" x 11/2" lag screws for rear track hangers
Ten 10d 3" nails
Stop Molding
• Wood Block
• Rope
3
G01-R01-0704
You can install your new garage door yourself IF…
a) you have help (it may weigh up to 500 lbs.);
b) you have the right tools and reasonable mechanical
aptitude or experience; and
c) you follow these instructions very carefully.
Garage doors use springs to balance them. There are
two types of springs installed — extension or torsion.
Each of these is available in either a standard or EZ-Set
TM
assembly option. Please look at the drawings on page 8 to
see which springs your old door has.
If your old door uses torsion springs, do not attempt
to remove the door or the springs yourself. Have a
quali ed door repair service remove them. Attempting to
remove a torsion spring assembly without proper training
or tools may result in an uncontrolled release of spring
forces which can cause serious or fatal injury.
Only the track speci ed and supplied with the door
should be used.
The brackets at the bottom corners of your garage door
are under great tension. Do not attempt to loosen any
bracket fasteners except when and as directed in
detail in the following instructions. Otherwise, the
bracket could spring out with dangerous force.
Do not permit children to play beneath or with any
garage door or electric operating controls.
In removing a garage door that has extension springs,
follow the instructions carefully, including the use of “C”
clamps or locking pliers on both sides of the door in
order to keep the door from moving once the springs are
removed.
Keep hands and ngers clear of section joints, track, and
other door parts when the door is opening and closing to
avoid injury. The lift handles are located for safe operation
as well as easy use.
Bolts must be installed at the rear end of horizontal tracks.
These act to stop the rollers and keep the door from rolling
off the back of the track.
Track installations must use sway braces on the rear track
hangers to prevent sideways movement. If the tracks are
not rmly stabilized they might spread, allowing the door
to fall and cause severe injury and damage.
Springs, cables, and bottom xtures are under strong
spring tension. Do not attempt to loosen any fasteners
on these components. You could suddenly release
spring forces and risk severe injury.
If the garage door and/or any of the supporting track
are damaged, operating the door could be hazardous.
Call an authorized representative of the manufacturer or
professional door repair service promptly.
If repairs are ever required to your door, safety and
trouble-free operation can be best assured by using
original replacement parts.
Once you have completed the installation of your new
garage door, please be sure that your garage complies
with all applicable ventilation requirements before you
enclose any vehicles in the garage. Good ventilation
avoids re and health hazards caused by fumes
accumulating within a well-sealed garage.
Clopay Building Products Company disclaims all liability
for any installation that is not in compliance with applicable
state or county building codes.
Doors equipped with automatic door operators can
cause serious injury or death if not properly adjusted and
operated. To ensure safety of these doors:
a) test the sensitivity of the operator’s safety reverse
mechanism monthly;
b) if your door has a pull down rope, you must remove
the pull down rope;
c) make sure the door remains unlocked;
d) do not allow children to play with the controls.
STEP 2 – READ THIS SAFETY INFORMATION
IMPORTANT!
To Protect Yourself From Injury You Must Carefully Read The Following Safety
Information and Warnings Before You Install Or Use Your New Garage Door
In the interest of safety this symbol means WARNING or
CAUTION. Personal injury and/or property damage may
occur unless instructions are followed carefully.
4
WARNING
G01-R02-0905
STEP 3 – Check Headroom/ Backroom/
Sideroom
Headroom is the space needed above the top of the door for
the door, the overhead tracks, and the springs. Measure to
check that there are no obstructions in your garage within that
space. The normal headroom space requirement is shown in
Table 3-A. The backroom distance is measured from the back
of the door into the garage, and should be at least 18" more
than the height of the garage door. A minimum sideroom of
3-3/4" (5-1/2" for EZ-Set™ Extension Spring) should be
available on each side of the door on the interior wall surface
to allow for attachment of the vertical track assembly. The
rough opening should be the same size as the door. (FIG. 3-A)
Track Radius: The radius of your track can be determined by
measuring the dimension “R” in FIG. 3-B. If dimension “R”
measures 11" to 12", then you have a 12" radius track. If “R”
equals 14" to 15", then you have a 15" radius track. (FIG. 3-B)
Headroom requirements
The standard headroom space requirement is shown in Table
3-A at right. (See page 8 if you have a question on which type
of spring you have.)
Low Headroom? If you have restricted headroom, several
remedies are available. See Table 3-B for various options.
NOTE: Installation of the various Low Headroom Options
differs from the installation of a standard headroom door.
Supplemental instructions are included with the hardware of
each Low Headroom Option.
Table 3-A: Standard Headroom
Requirement Chart
Table 3-B: Low Headroom Options*
FIG. 3-B
FIG. 3-A
R
Rough Opening = Door Size
Backroom = Door
Height Plus 18"
Headroom
Required
Door
Height
Reduces Required
Spring Type Low Headroom Option Headroom to: How can I get this option?
Extension and EZ-Set™ Low Headroom Track 4-1/2" Order Low Headroom Track.
Extension
Extension and EZ-Set™ Low Headroom Conversion Kit 4-1/2" Available at most retail stores.
Extension (Modi es Standard Track)
Extension and EZ-Set™ Quick Turn Bracket 8" on 12" Radius Track Order Quick Turn Bracket Set.
Extension
EZ-Set™ Torsion Low Headroom Track 9-1/2" Order Low Headroom Track.
(Front Mount Spring)
EZ-Set™ Torsion Low Headroom Conversion Kit 9-1/2" Available at most retail stores.
(Modi es Standard Track)
Torsion Low Headroom Track 9-1/2" Available from and should be
(Front Mount Spring) installed by professional installer only.
Torsion Low Headroom Track 4-1/2” Available from and should be
(Rear Mount Spring) installed by professional installer only.
5
Track Headroom
Spring Type Radius Required
EZ-Set™ Extension Spring or 12" 10"
Extension Spring
EZ-Set™ Extension Spring or 15" 12"
Extension Spring
EZ-Set™ Torsion Spring or 12" 12"
Torsion Spring
EZ-Set™ Torsion Spring or 15" 14"
Torsion Spring
3-3/4" Minimum Side Room
(5-1/2" Minimum for EZ-Set™
Extension Spring)
*About 3" of additional headroom height at the center plus additional backroom is needed to install an automatic garage door
opener. Check door opener instructions.
G01-R01-0704
STEP 4 – Removing the Existing Door
Springs
Garage doors use springs to balance the door weight. There
are two types of springs used — extension and torsion. Each
of these is available in either a standard or EZ-Set
TM
assembly
option. Please look at the drawings on page 8 to see which
springs your old door has installed. If your present door uses
standard torsion springs, do not attempt to remove the
door or the springs yourself. They should be removed by
a quali ed door service professional. Attempting to remove a
torsion spring assembly without proper training and tools may
result in an uncontrolled release of spring forces which can
cause serious or fatal injury.
Extension springs and EZ-Set
TM
Springs are shown on a
sectional garage door in the illustration on page 8 to see which
springs your door has. The following instructions detail how to
remove these springs.
Serious injury could result if spring tension has not been
released before other work begins.
Removing Extension Springs
Use two or more helpers to assist you in lowering
the door.
Step 4-1a: Raise the door to the full open position. Place “C”
clamps or locking pliers tightly on both sides of the track under
the door so the door is held securely in place. With the door
fully open, most spring tension has been removed. (FIG. 4-A)
Do not attempt to remove or adjust extension springs with door
in the down position. Use “C” clamps to keep the door from
moving or falling once the springs are removed.
Step 4-2: Detach the cable at both ends. Disassemble and
remove the springs and cable completely from the door.
NOTE: Wood blocks should be placed underneath the door
when closing to prevent ngers from being trapped.
Step 4-3: Remove the “C” clamps from the track and carefully
close the door.
Some large doors might weigh as much as 500 pounds when
the spring tension is removed. The weight of the door will not
be apparent when you rst begin to close the door. The door
will feel progressively heavier as it is lowered until its full weight
(as much as 500 pounds) is realized about one foot from the
oor. A single car door may weigh as much as 200 pounds.
(FIG. 4-B)
To avoid injury, keep hands and ngers clear of section
joints, track, and other door parts while the door is
opening and closing.
WARNING
WARNING
WARNING
WARNING
Removing EZ-Set
TM
Extension or Torsion
Springs
Step 4-1b: With the door in the DOWN position, position a
drill with a 7/16” socket bit over the worm drive. Using the
reverse (counter-clockwise) direction on the drill, remove all
the tension from the spring (repeat for each side). After spring
tension has been removed, detach the lift cables at both ends.
Disassemble and remove the springs and cable completely
from the door. (FIG. 4-C)
FIG. 4-A
FIG. 4-B
FIG. 4-C
Wood
Block
“C” Clamp
Black
Housing
Lifting
Cable
Sheave
Fork
Sheave
Black
Bushing
Red Mark
on Safety
Cable
Safety
Cable
Worm
Drive
6
7
STEP 5 - Removing Door Sections & Track
Step 5-1: The door can now be disassembled. Starting with
the top section, remove the hardware and unstack the sections
one at a time. (FIG. 5-A)
Step 5-2: After all sections have been removed from the
opening, detach all remaining track and hardware from the
jambs. The hangers that attach the rear ends of the overhead
track to the ceiling (called rear track hangers) in many cases
can be reused on the new door if made of 13 gauge (3/32") or
heavier steel and is not loose or unstable. (FIG. 5-B)
To avoid installation problems which could result in
personal injury or property damage, use only the track
speci ed and supplied with the door. Do not attempt to
reuse old track.
STEP 6 - Preparing the Opening
Step 6-1: On the inside of the garage your opening should
be framed with wood jambs, 2" x 6" if possible. The side
jambs should extend to approximately the same height as the
headroom required. If you have just removed an old door, the
jambs should be inspected for the condition of the wood. If the
wood is rotten, it should be replaced now. The jambs should
be plumb and the header should be level. If there are any
bolts fastening the jambs to the wall, the heads should be
ush so they don’t interfere with the installation of your new
door. (FIG. 6-A)
NOTE: Rough opening (without stop molding) = Door size
Step 6-2: Door stop molding should be temporarily nailed to
the edges of the jambs ush with the inside. (FIG. 6-B)
Stop molding featuring a built-in weather seal is offered as
an option.
WARNING
FIG. 6-B
FIG. 5-B
FIG. 5-A
Rear Track
Hanger
Outside
Inside
Stop
Molding
FIG. 6-A
8"
Minimum
Center
Post
(With
Two
Doors
Side By
Side)
2 x 6
“Header Jamb”
Opening
Height
Inside of Garage
Looking Out
2 x 6
“Side Jamb”
Opening
Width
3-3/4" Minimum
Side Room (5-1/2"
Minimum for EZ-Set
TM
Extension Spring)
P03-R01-0704
STEP 10 - Reinforcing the Top Section
for Opener
To avoid damage to your door, you must reinforce the top
section of the door in order to provide a mounting point for the
opener to be attached. You will need one (1), two (2), or three
(3) pieces of 1-1/4” x 1-1/4” minimum punched angle at least
13 gauge or 3/32” thick from your local hardware or building
supply store. Figures 10-B to 10-E show how punched angle
is to be af xed to door.
Horizontal Angle Attachment
Attach the horizontal punched angle (the longer piece) to the
top section as shown in Figure 10-A. Angle iron may need to
be trimmed depending on door section height and distance
between center stiles. Some doors with struts may not need
a horizontal angle; see Figures 10-B to 10-E to identify the
attachment method for your speci c door.
Do NOT install the bracket supplied with the opener.
Failure to reinforce the door, as illustrated, will void your
warranty.
Required Materials:
(1) 18" or 21" length of angle iron,
(2) #14 x 5/8” sheet metal screws, and
(2) 1/4” x 3/4” self tapping screws.
1/4" Lock
Washer
Horizontal
Punched Angle
1/4" Nut
1/4" x 1" Bolt*
Punched Angle
for Operator Draw
Bar Attachment
15'0'' up to 15'10'' & 19'0'' up to 20'0''
Wide Doors with Strut
5''
Strut
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
16'0'' up to 18'0'' Wide
Doors with Strut
Strut
5''
18'' or 21''
Long
18'' or 21''
Long
Required materials:
(2) 18” or 21” lengths of angle iron,
(2) ¼’’x1’ bolts, (2) ¼’ lock washers, (2) ¼’’ nuts,
(4) #14 x 5/8” sheet metal screws, and
(4) 1/4” x 3/4” self tapping screws.
*Fully-insulated doors use 1/4” x 3/4” self taping screw.
NOTE: An opener bracket kit speci cally designed for
opener attachment may be purchased as an option
(silver galvanized or white powder coated).
Instructions are provided with the kit.
NOTE: Operator may be attached up to 2 feet off center.
(Doors with Torsion Springs Only)
FIG. 10-A – Horizontal Reinforcement Attachment
(Top of Door Section – Side View)
FIG. 10-C
FIG. 10-E
Required materials:
(2) 18” or 21” and (1) 27” or 50” length of angle iron
(4) 1/4’’x1’ bolts, (4) 1/4’ lock washers, (4) 1/4’’ nuts, and
(8) #14 x 5/8” sheet metal screws.
8'0'' up to 9'0'' Wide Doors
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
2"
48'' Long
Punched Angle
for Operator Draw
Bar Attachment
10'0'' up to 14'10'' Wide Doors
27'' or 50''
Long
27'' or 50''
Long
27'' or 50''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
2"
Required materials:
(1) 18’’ or 21’ and (1) 48’ length of angle iron,
(6) ¼’’x1’ bolts, (6) ¼’ lock washers, (6) ¼’’ nuts, and
(4) #14 x 5/8” sheet metal screws.
FIG. 10-B
FIG. 10-D
14
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
P03-R02-0509
P03-R01-0704
Right (Black)
Cable Drum
Black Winding
Cone
Center Bearing Plate
Stationar
y
Cone
Standard Torsion Spring System
Left (Red)
Cable Drum
End Bearing Plates
Red Winding
Cone
Torsion Tube
EZ-Set™ Extension Spring System
EZ-Set™ Winding Unit
Sheave
Standard Extension Spring System
Stationary Sheave
Sheave
NOTE: The above illustration represents a composite of many of the features found on a variety of garage doors. While not
representative of any one door, it provides a handy reference for the location of speci c components
8
EZ-Set™ Torsion Spring System
EZ-Set™
Winding Unit
Left Cable Drum
EZ-Set™ Bracket
Containment Cable
Typical Garage Door Installation Illustration
Extension Spring System Shown on Complete Door
Rear Track Hanger
(Not Included)
Extension Spring
Sheave
Stationary Sheave
Horizontal Track
Door Jamb
Flag Bracket
Vertical TrackVertical Track
Top Bracket
#3 Hinge
#2 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
Inside Step
Plate
Inside Step
Plate
Inside Step
Plate
Inside Step
Plate
#3 Hinge
#2 Hinge
#1 Hinge
Long Track Bracket
Short Track Bracket
Safety Label
Bottom Brackets
Section #3
Section #4
Safety Label
Section #2
Section #1
P03-R01-0704
STEP 9 - Installing Door Sections
(Continued)
Step 9-6: Place the second section on top of the rst section.
Drive a 3” nail in the jambs at each end and bend it over the
edges of the section to hold the section in place. Attach the
hinges from the top of the rst section to the bottom of the
second. (FIG. 9-D)
Step 9-7: Place the third section on saw horses. Attach #3
hinges to the ends at the top edge and #1 hinges to all other
stiles along the top edge using #14 x 5/8” sheet metal screws.
(FIG. 9-E)
NOTE: If your door was supplied with more than 1 strut
(consult Table 7-A on bottom of page 10), use 1/4” x 3/4” self
tapping screws to attach strut as shown in the illustration.
When pre-drilled holes in strut do not line up vertically with
stiles, you will be required to drill (2) 3/16” pilot holes through
the strut and the stile at each end stile and each center stile,
or use a drill or impact wrench with a 7/16” socket to drive
self-tapping screws through strut and stile. (FIG. 9-E)
Step 9-8: Place the third section on top of the other sections
and nail in place as before. Attach the hinges from the top of
the previous section to the bottom of this section. (FIG. 9-D)
If you have two sections left, repeat Steps 9-7 and 9-8 using
#4 hinges on the end of the top edge and #1 hinges to all other
stiles along the top edge.
Step 9-9: Place the last section on the saw horses. Attach the
top roller brackets as shown. The top roller brackets are to be
attached with three (insulated doors) or four (non-insulated
doors) #14 x 5/8” sheet metal screws. The top of the bracket
should be located 3-1/4” down from the top of the door. The
bottom of the bracket goes in smaller holes 6-1/4” from top of
section. (FIG. 9-F)
If your door was supplied with any struts (consult Table 7-A
on bottom of page 10), use 1/4” x 3/4” self tapping screws
to attach strut as shown in the illustration. When pre-drilled
holes in strut do not line up vertically with stiles, you will be
required to drill (2) 3/16” pilot holes through the strut and the
stile at each end stile and each center stile, or use a drill or
impact wrench with a 7/16” socket to drive self-tapping screws
through strut and stile. (FIG. 9-F)
Step 9-10: Place a roller in the top and bottom brackets and
in the tubes in each of the hinges at the ends of each section.
Some hinges have two tubes. Place the roller in the tube that is
farthest from the face of the door. (FIG 9-G)
Safety
Label
FIG. 9-D
FIG. 9-E
13
Top Bracket
#1 HingeBottom Bracket
#2, 3, or 4 Hinge
FIG. 9-G
1/4" x 3/4"
Self Tapping Screws
Strut
(
if necessar
y)
#3 Hin
g
e
#1 Hin
g
e
P03-R01-0704
9
Track Bracket
(Longer)
Track Bracket
(Shorter)
#2 Hinge
#3 Hinge
#4 Hinge
(5 Section
Doors Only)
Top Bracket
3/8"-18 x 3/4"
Lg. Carriage Bolt
Bottom Bracket
(1) LH + (1) RH
Flag
Bracket
(1) LH +
(1) RH
Cable Assembly
Vertical
Track
Curved
Horizontal Track
3/8" Washer
Horizontal Angle
Struts*
1/4" x 3/4"
Hex Head
Self-Tapping
Screw
#14 x 5/8"
Hex Head
Sheet Metal
Screw
1/4" Flange Nut
3/8" Hex Nut
Lift Handle
Inside
Step Plate
1/4" x 5/8"
Track Bolt
5/16" x 1-5/8"
Lag Bolt
#1 Hinge
Rollers
Description
Description:Qty. Qty.
Door Size:Door Size:
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
4 Section Doors
5 Section Doors
Pull Rope
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
5 Section Doors
4 Section Doors
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0"H
All Doors
All Doors
All Doors
Keyed Lock Kit (If included,
parts are detailed in Lock
instructions)
All Doors
All Doors Will Receive (2) Of These Items:
(While not representative of any one model, the quantities below can be used as a guide. In some
instances, extra screws/bolts are provided in the event of strip out or loss of parts.)
*More struts may be required in high windload areas.
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
10
12
5
11
1 or 2
16
22
10
12
1 or 2 0 or 1
16
22
0
10
56
90
0
1
1
Hardware Components
NOTE: All doors will receive (1) spring kit and (1) or more springs. Separate spring installation supplemental
instructions should be included with door hardware. This supplement contains a list of all spring related hardware
along with instructions on proper spring installation.
P03-R01-0704
STEP 9 - Installing Door Sections
Step 9-1: Place the section in the opening so that it is against
the stop molding and centered from side to side. Place a level
on the section and use a piece of wood under one end or the
other (if necessary) to make the section level. (FIG. 9-A)
Step 9-2: Remove the level and drive a 3” nail in the jambs at
each end and bend it over the edge of the section to hold the
section in place. (FIG. 9-B)
NOTE: These nails are all that will hold the stacked door
section in place until the tracks are secured to the back jambs.
Be sure the nails hold the sections rmly in position.
Step 9-3: With the Table 9-A below, determine the order in
which you will attach the remaining sections.
NOTE: If a lock assembly was ordered with the door, the holes
for the lock may be predrilled. (Lock templates are included in
the lock instructions for doors without predrilled holes.)
* Section with general safety label.
Step 9-4: Place the next section face down on the saw horses.
If your door is predrilled for a lock, this section will be the one
with holes in the center of the panel face. Identify the bottom
edge as shown in the illustration. (FIG. 9-C)
Attach a number 2 hinge to each end at the top edge using
#14 x 5/8" sheet metal screws. Remember that the number
is stamped on the side of the hinge that is to be attached to
the section. Attach a number 1 hinge to at each center stile
location along the top edge of the section.
Step 9-5: Keyed Lock Installation. If you wish to install a
keyed lock, begin the lock installation now according to the
supplemental instructions included with the lock hardware. If
your door did not come with a keyed lock, install lift handle as
shown on previous page.
1st 2nd
Door (Bottom) (Lock) 3rd 4th 5th
Height Section Section Section* Section Section
6'0" 18" 18" 18" 18" -
6'3" 18" 18" 18" 21" -
6'6" 21" 18" 18" 21" -
6'9" 21" 21" 18" 21" -
7'0" 21" 21" 21" 21" -
7'6" 18" 18" 18" 18" 18"
7'9" 18" 18" 18" 18" 21"
8'0" 21" 18" 18" 18" 21"
FIG. 9-A
33
Bottom
Edge
Center Stile
End
Stile
#2 Hinge
#1 Hinge
Stop Molding
12
Table 9-A - Section Order for Various Door Heights
FIG. 9-B
FIG. 9-C
P03-R01-0704
STEP 7 - Preparing Bottom Door Section
Step 7-1: Spread the hardware on the garage oor in groups
so that you can easily nd the parts.
Step 7-2: Find the section with the aluminum weatherstrip
retainer fastened to one edge. The aluminum weatherstrip
retainer is on the bottom edge of the bottom section. Place the
section on saw horses face down. (FIG. 7-A) Be sure to cover
saw horses with carpet or cloth so as not to scratch section.
Step 7-3: Bend and break apart bottom brackets by hand
along end tabs as shown. (FIG. 7-B) Be sure to remove
connecting tab.
Step 7-4: Insert safety tabs on bottom bracket into slots on end
stile of door. Slide bottom bracket up to fully engage tabs. (FIG.
7-C) Attach all hardware with #14 x 5/8” sheet metal screws.
Attach the bottom brackets with two screws to the bottom
corners of the section. Screws go into the end stiles. Hook
the looped ends of the steel lift cable over the buttons on the
bottom brackets. (If your door came with standard extension
springs, the lift cables are the longer and smaller diameter
of the two sets of cable. If your door came with EZ-Set™
Extension Springs, do NOT attach lift cables at this time! Do
NOT use the shorter safety containment cables as lift cables,
as this can cause improper door function). (FIG. 7-D)
Failure to properly engage safety tabs on bottom bracket
into slots on edge of door can result in severe injury when
spring tension is applied.
Step 7-5: Hinges are identi ed by number 1, 2, 3 (and
sometimes 4, on 5 section doors only). This number is
stamped on the hinge. Attach a number 1 hinge at each center
stile location along the top edge of the section using #14 x 5/8”
sheet metal screws. The number is stamped on the side of the
hinge that is to be attached to the section. (FIG. 7-E)
NOTE: If Table 7-A below shows a need for a reinforcing strut
on the bottom section, it should be attached just above bottom
brackets. Use 1/4” x 3/4” self tapping screws to attach strut as
shown in the illustration. When pre-drilled holes in strut do not
line up vertically with stiles, you will be required to drill (2) 3/16”
pilot holes through the strut and the stile at each end stile and
each center stile, or use a drill or impact wrench with a 7/16”
socket to drive self-tapping screws through strut and stile.
(FIG. 7-E)
NOTE: Doors installed in high windload regions (Florida
and other high wind prone areas) may require additional
reinforcement beyond what is detailed in these instructions.
Please refer to supplemental windload instructions for these
areas.
WARNING
1/4" x 3/4"
Self Tapping
Screws
(2 per Stile)
#1 Hinge
Center Stile
Strut
(if necessary)
End Stile
FIG. 7-E
FIG. 7-D
FIG. 7-C
FIG. 7-B
FIG. 7-A
Door Width Bottom Section 3rd Section Top Section
15 & 16 ft. - -
17 & 18 ft. ✓ ✓
Over 18 ft. 2 in. – One strut per section
Table 7-A - Sections Requiring Struts
Aluminum Weatherstrip Retainer
#14 x 5/8" Sheet Metal Screws
Weatherstrip
Safety Tabs
Bottom
Bracket
#14 x 5/8” Sheet Metal Screw
Bottom Section
10
Slots
P03-R01-0704
STEP 8 - Lift Handle Attachment
Bottom Section
From the front of the door section, drill (2) 1/2" holes through
the section according to the Bottom Section Hole Pattern
(FIG. 8-B). A T-Square should be used to ensure that they are
vertically in line. If your door has an outside keyed lock, the
hole pattern should be drilled on the bottom section directly
below the lock. If your door does not have an outside keyed
lock, the hole pattern should be drilled directly below the hinge
closest to the horizontal center of the door. Install the lift handle
& inside step plate assembly using (2) #14 x 5/8" sheet metal
screws (Fig. 8-A).
IMPORTANT: Use a wrench or a socket to drive screws.
Do not over tighten. Do not use an electric drill or driver.
2nd Section (to be installed at the completion of Step 9-4.
Not Required on Doors with Outside Keyed Lock)
From the front of the door section, drill (2) 1/2" holes through
the section according to the 2nd Section Hole Pattern (FIG.
8-B). A T-Square should be used to ensure that they are
vertically in line. The hole pattern should be drilled directly
above the hinge closest to the horizontal center of the door.
Install the lift handle / inside step plate assembly using (2) #14
x 5/8" sheet metal screws (Fig. 8-A).
Painting Lift Handles
Plastic Lift Handles can be painted using a quality spray on or
brushed on enamel paint.
Lift Handle Hole Drilling Pattern
Outside View
2nd Section
Bottom Section
Measure to Hinge Holes
On Opposite Side
Measure to Hinge Holes
On Opposite Side
3/4"
3/4"
Center Line Of
2nd Section
OR
2-3/4" Offset Of
Bottom Edge
Of Door
1/2" Dia.
Lift
Handle
Lift
Handle
Inside
Step
Plate
2nd Section
Inside Step
Plate
#14 x 5/8"
Sheet Metal
Screw
Bottom Section
FIG. 8-B
FIG. 8-A
11
P03-R01-0704
STEP 7 - Preparing Bottom Door Section
Step 7-1: Spread the hardware on the garage oor in groups
so that you can easily nd the parts.
Step 7-2: Find the section with the aluminum weatherstrip
retainer fastened to one edge. The aluminum weatherstrip
retainer is on the bottom edge of the bottom section. Place the
section on saw horses face down. (FIG. 7-A) Be sure to cover
saw horses with carpet or cloth so as not to scratch section.
Step 7-3: Bend and break apart bottom brackets by hand
along end tabs as shown. (FIG. 7-B) Be sure to remove
connecting tab.
Step 7-4: Insert safety tabs on bottom bracket into slots on end
stile of door. Slide bottom bracket up to fully engage tabs. (FIG.
7-C) Attach all hardware with #14 x 5/8” sheet metal screws.
Attach the bottom brackets with two screws to the bottom
corners of the section. Screws go into the end stiles. Hook
the looped ends of the steel lift cable over the buttons on the
bottom brackets. (If your door came with standard extension
springs, the lift cables are the longer and smaller diameter
of the two sets of cable. If your door came with EZ-Set™
Extension Springs, do NOT attach lift cables at this time! Do
NOT use the shorter safety containment cables as lift cables,
as this can cause improper door function). (FIG. 7-D)
Failure to properly engage safety tabs on bottom bracket
into slots on edge of door can result in severe injury when
spring tension is applied.
Step 7-5: Hinges are identi ed by number 1, 2, 3 (and
sometimes 4, on 5 section doors only). This number is
stamped on the hinge. Attach a number 1 hinge at each center
stile location along the top edge of the section using #14 x 5/8”
sheet metal screws. The number is stamped on the side of the
hinge that is to be attached to the section. (FIG. 7-E)
NOTE: If Table 7-A below shows a need for a reinforcing strut
on the bottom section, it should be attached just above bottom
brackets. Use 1/4” x 3/4” self tapping screws to attach strut as
shown in the illustration. When pre-drilled holes in strut do not
line up vertically with stiles, you will be required to drill (2) 3/16”
pilot holes through the strut and the stile at each end stile and
each center stile, or use a drill or impact wrench with a 7/16”
socket to drive self-tapping screws through strut and stile.
(FIG. 7-E)
NOTE: Doors installed in high windload regions (Florida
and other high wind prone areas) may require additional
reinforcement beyond what is detailed in these instructions.
Please refer to supplemental windload instructions for these
areas.
WARNING
1/4" x 3/4"
Self Tapping
Screws
(2 per Stile)
#1 Hinge
Center Stile
Strut
(if necessary)
End Stile
FIG. 7-E
FIG. 7-D
FIG. 7-C
FIG. 7-B
FIG. 7-A
Door Width Bottom Section 3rd Section Top Section
15 & 16 ft. - -
17 & 18 ft. ✓ ✓
Over 18 ft. 2 in. – One strut per section
Table 7-A - Sections Requiring Struts
Aluminum Weatherstrip Retainer
#14 x 5/8" Sheet Metal Screws
Weatherstrip
Safety Tabs
Bottom
Bracket
#14 x 5/8” Sheet Metal Screw
Bottom Section
10
Slots
P03-R01-0704
STEP 8 - Lift Handle Attachment
Bottom Section
From the front of the door section, drill (2) 1/2" holes through
the section according to the Bottom Section Hole Pattern
(FIG. 8-B). A T-Square should be used to ensure that they are
vertically in line. If your door has an outside keyed lock, the
hole pattern should be drilled on the bottom section directly
below the lock. If your door does not have an outside keyed
lock, the hole pattern should be drilled directly below the hinge
closest to the horizontal center of the door. Install the lift handle
& inside step plate assembly using (2) #14 x 5/8" sheet metal
screws (Fig. 8-A).
IMPORTANT: Use a wrench or a socket to drive screws.
Do not over tighten. Do not use an electric drill or driver.
2nd Section (to be installed at the completion of Step 9-4.
Not Required on Doors with Outside Keyed Lock)
From the front of the door section, drill (2) 1/2" holes through
the section according to the 2nd Section Hole Pattern (FIG.
8-B). A T-Square should be used to ensure that they are
vertically in line. The hole pattern should be drilled directly
above the hinge closest to the horizontal center of the door.
Install the lift handle / inside step plate assembly using (2) #14
x 5/8" sheet metal screws (Fig. 8-A).
Painting Lift Handles
Plastic Lift Handles can be painted using a quality spray on or
brushed on enamel paint.
Lift Handle Hole Drilling Pattern
Outside View
2nd Section
Bottom Section
Measure to Hinge Holes
On Opposite Side
Measure to Hinge Holes
On Opposite Side
3/4"
3/4"
Center Line Of
2nd Section
OR
2-3/4" Offset Of
Bottom Edge
Of Door
1/2" Dia.
Lift
Handle
Lift
Handle
Inside
Step
Plate
2nd Section
Inside Step
Plate
#14 x 5/8"
Sheet Metal
Screw
Bottom Section
FIG. 8-B
FIG. 8-A
11
P03-R01-0704
9
Track Bracket
(Longer)
Track Bracket
(Shorter)
#2 Hinge
#3 Hinge
#4 Hinge
(5 Section
Doors Only)
Top Bracket
3/8"-18 x 3/4"
Lg. Carriage Bolt
Bottom Bracket
(1) LH + (1) RH
Flag
Bracket
(1) LH +
(1) RH
Cable Assembly
Vertical
Track
Curved
Horizontal Track
3/8" Washer
Horizontal Angle
Struts*
1/4" x 3/4"
Hex Head
Self-Tapping
Screw
#14 x 5/8"
Hex Head
Sheet Metal
Screw
1/4" Flange Nut
3/8" Hex Nut
Lift Handle
Inside
Step Plate
1/4" x 5/8"
Track Bolt
5/16" x 1-5/8"
Lag Bolt
#1 Hinge
Rollers
Description
Description:Qty. Qty.
Door Size:Door Size:
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
4 Section Doors
5 Section Doors
Pull Rope
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
5 Section Doors
4 Section Doors
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0"H
All Doors
All Doors
All Doors
Keyed Lock Kit (If included,
parts are detailed in Lock
instructions)
All Doors
All Doors Will Receive (2) Of These Items:
(While not representative of any one model, the quantities below can be used as a guide. In some
instances, extra screws/bolts are provided in the event of strip out or loss of parts.)
*More struts may be required in high windload areas.
Single Car Doors
8' - 9'W x 6'6'' - 7'0''H
Double Car Doors
16'W x 6'6" - 7'0''H
10
12
5
11
1 or 2
16
22
10
12
1 or 2 0 or 1
16
22
0
10
56
90
0
1
1
Hardware Components
NOTE: All doors will receive (1) spring kit and (1) or more springs. Separate spring installation supplemental
instructions should be included with door hardware. This supplement contains a list of all spring related hardware
along with instructions on proper spring installation.
P03-R01-0704
STEP 9 - Installing Door Sections
Step 9-1: Place the section in the opening so that it is against
the stop molding and centered from side to side. Place a level
on the section and use a piece of wood under one end or the
other (if necessary) to make the section level. (FIG. 9-A)
Step 9-2: Remove the level and drive a 3” nail in the jambs at
each end and bend it over the edge of the section to hold the
section in place. (FIG. 9-B)
NOTE: These nails are all that will hold the stacked door
section in place until the tracks are secured to the back jambs.
Be sure the nails hold the sections rmly in position.
Step 9-3: With the Table 9-A below, determine the order in
which you will attach the remaining sections.
NOTE: If a lock assembly was ordered with the door, the holes
for the lock may be predrilled. (Lock templates are included in
the lock instructions for doors without predrilled holes.)
* Section with general safety label.
Step 9-4: Place the next section face down on the saw horses.
If your door is predrilled for a lock, this section will be the one
with holes in the center of the panel face. Identify the bottom
edge as shown in the illustration. (FIG. 9-C)
Attach a number 2 hinge to each end at the top edge using
#14 x 5/8" sheet metal screws. Remember that the number
is stamped on the side of the hinge that is to be attached to
the section. Attach a number 1 hinge to at each center stile
location along the top edge of the section.
Step 9-5: Keyed Lock Installation. If you wish to install a
keyed lock, begin the lock installation now according to the
supplemental instructions included with the lock hardware. If
your door did not come with a keyed lock, install lift handle as
shown on previous page.
1st 2nd
Door (Bottom) (Lock) 3rd 4th 5th
Height Section Section Section* Section Section
6'0" 18" 18" 18" 18" -
6'3" 18" 18" 18" 21" -
6'6" 21" 18" 18" 21" -
6'9" 21" 21" 18" 21" -
7'0" 21" 21" 21" 21" -
7'6" 18" 18" 18" 18" 18"
7'9" 18" 18" 18" 18" 21"
8'0" 21" 18" 18" 18" 21"
FIG. 9-A
33
Bottom
Edge
Center Stile
End
Stile
#2 Hinge
#1 Hinge
Stop Molding
12
Table 9-A - Section Order for Various Door Heights
FIG. 9-B
FIG. 9-C
P03-R01-0704
Right (Black)
Cable Drum
Black Winding
Cone
Center Bearing Plate
Stationar
y
Cone
Standard Torsion Spring System
Left (Red)
Cable Drum
End Bearing Plates
Red Winding
Cone
Torsion Tube
EZ-Set™ Extension Spring System
EZ-Set™ Winding Unit
Sheave
Standard Extension Spring System
Stationary Sheave
Sheave
NOTE: The above illustration represents a composite of many of the features found on a variety of garage doors. While not
representative of any one door, it provides a handy reference for the location of speci c components
8
EZ-Set™ Torsion Spring System
EZ-Set™
Winding Unit
Left Cable Drum
EZ-Set™ Bracket
Containment Cable
Typical Garage Door Installation Illustration
Extension Spring System Shown on Complete Door
Rear Track Hanger
(Not Included)
Extension Spring
Sheave
Stationary Sheave
Horizontal Track
Door Jamb
Flag Bracket
Vertical TrackVertical Track
Top Bracket
#3 Hinge
#2 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
#1 Hinge
Inside Step
Plate
Inside Step
Plate
Inside Step
Plate
Inside Step
Plate
#3 Hinge
#2 Hinge
#1 Hinge
Long Track Bracket
Short Track Bracket
Safety Label
Bottom Brackets
Section #3
Section #4
Safety Label
Section #2
Section #1
P03-R01-0704
STEP 9 - Installing Door Sections
(Continued)
Step 9-6: Place the second section on top of the rst section.
Drive a 3” nail in the jambs at each end and bend it over the
edges of the section to hold the section in place. Attach the
hinges from the top of the rst section to the bottom of the
second. (FIG. 9-D)
Step 9-7: Place the third section on saw horses. Attach #3
hinges to the ends at the top edge and #1 hinges to all other
stiles along the top edge using #14 x 5/8” sheet metal screws.
(FIG. 9-E)
NOTE: If your door was supplied with more than 1 strut
(consult Table 7-A on bottom of page 10), use 1/4” x 3/4” self
tapping screws to attach strut as shown in the illustration.
When pre-drilled holes in strut do not line up vertically with
stiles, you will be required to drill (2) 3/16” pilot holes through
the strut and the stile at each end stile and each center stile,
or use a drill or impact wrench with a 7/16” socket to drive
self-tapping screws through strut and stile. (FIG. 9-E)
Step 9-8: Place the third section on top of the other sections
and nail in place as before. Attach the hinges from the top of
the previous section to the bottom of this section. (FIG. 9-D)
If you have two sections left, repeat Steps 9-7 and 9-8 using
#4 hinges on the end of the top edge and #1 hinges to all other
stiles along the top edge.
Step 9-9: Place the last section on the saw horses. Attach the
top roller brackets as shown. The top roller brackets are to be
attached with three (insulated doors) or four (non-insulated
doors) #14 x 5/8” sheet metal screws. The top of the bracket
should be located 3-1/4” down from the top of the door. The
bottom of the bracket goes in smaller holes 6-1/4” from top of
section. (FIG. 9-F)
If your door was supplied with any struts (consult Table 7-A
on bottom of page 10), use 1/4” x 3/4” self tapping screws
to attach strut as shown in the illustration. When pre-drilled
holes in strut do not line up vertically with stiles, you will be
required to drill (2) 3/16” pilot holes through the strut and the
stile at each end stile and each center stile, or use a drill or
impact wrench with a 7/16” socket to drive self-tapping screws
through strut and stile. (FIG. 9-F)
Step 9-10: Place a roller in the top and bottom brackets and
in the tubes in each of the hinges at the ends of each section.
Some hinges have two tubes. Place the roller in the tube that is
farthest from the face of the door. (FIG 9-G)
Safety
Label
FIG. 9-D
FIG. 9-E
13
Top Bracket
#1 HingeBottom Bracket
#2, 3, or 4 Hinge
FIG. 9-G
1/4" x 3/4"
Self Tapping Screws
Strut
(
if necessar
y)
#3 Hin
g
e
#1 Hin
g
e
7
STEP 5 - Removing Door Sections & Track
Step 5-1: The door can now be disassembled. Starting with
the top section, remove the hardware and unstack the sections
one at a time. (FIG. 5-A)
Step 5-2: After all sections have been removed from the
opening, detach all remaining track and hardware from the
jambs. The hangers that attach the rear ends of the overhead
track to the ceiling (called rear track hangers) in many cases
can be reused on the new door if made of 13 gauge (3/32") or
heavier steel and is not loose or unstable. (FIG. 5-B)
To avoid installation problems which could result in
personal injury or property damage, use only the track
speci ed and supplied with the door. Do not attempt to
reuse old track.
STEP 6 - Preparing the Opening
Step 6-1: On the inside of the garage your opening should
be framed with wood jambs, 2" x 6" if possible. The side
jambs should extend to approximately the same height as the
headroom required. If you have just removed an old door, the
jambs should be inspected for the condition of the wood. If the
wood is rotten, it should be replaced now. The jambs should
be plumb and the header should be level. If there are any
bolts fastening the jambs to the wall, the heads should be
ush so they don’t interfere with the installation of your new
door. (FIG. 6-A)
NOTE: Rough opening (without stop molding) = Door size
Step 6-2: Door stop molding should be temporarily nailed to
the edges of the jambs ush with the inside. (FIG. 6-B)
Stop molding featuring a built-in weather seal is offered as
an option.
WARNING
FIG. 6-B
FIG. 5-B
FIG. 5-A
Rear Track
Hanger
Outside
Inside
Stop
Molding
FIG. 6-A
8"
Minimum
Center
Post
(With
Two
Doors
Side By
Side)
2 x 6
“Header Jamb”
Opening
Height
Inside of Garage
Looking Out
2 x 6
“Side Jamb”
Opening
Width
3-3/4" Minimum
Side Room (5-1/2"
Minimum for EZ-Set
TM
Extension Spring)
P03-R01-0704
STEP 10 - Reinforcing the Top Section
for Opener
To avoid damage to your door, you must reinforce the top
section of the door in order to provide a mounting point for the
opener to be attached. You will need one (1), two (2), or three
(3) pieces of 1-1/4” x 1-1/4” minimum punched angle at least
13 gauge or 3/32” thick from your local hardware or building
supply store. Figures 10-B to 10-E show how punched angle
is to be af xed to door.
Horizontal Angle Attachment
Attach the horizontal punched angle (the longer piece) to the
top section as shown in Figure 10-A. Angle iron may need to
be trimmed depending on door section height and distance
between center stiles. Some doors with struts may not need
a horizontal angle; see Figures 10-B to 10-E to identify the
attachment method for your speci c door.
Do NOT install the bracket supplied with the opener.
Failure to reinforce the door, as illustrated, will void your
warranty.
Required Materials:
(1) 18" or 21" length of angle iron,
(2) #14 x 5/8” sheet metal screws, and
(2) 1/4” x 3/4” self tapping screws.
1/4" Lock
Washer
Horizontal
Punched Angle
1/4" Nut
1/4" x 1" Bolt*
Punched Angle
for Operator Draw
Bar Attachment
15'0'' up to 15'10'' & 19'0'' up to 20'0''
Wide Doors with Strut
5''
Strut
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
16'0'' up to 18'0'' Wide
Doors with Strut
Strut
5''
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
Required materials:
(2) 18” or 21” lengths of angle iron,
(2) ¼’’x1’ bolts, (2) ¼’ lock washers, (2) ¼’’ nuts,
(4) #14 x 5/8” sheet metal screws, and
(4) 1/4” x 3/4” self tapping screws.
*Fully-insulated doors use 1/4” x 3/4” self taping screw.
NOTE: An opener bracket kit speci cally designed for
opener attachment may be purchased as an option
(silver galvanized or white powder coated).
Instructions are provided with the kit.
NOTE: Operator may be attached up to 2 feet off center.
(Doors with Torsion Springs Only)
FIG. 10-A – Horizontal Reinforcement Attachment
(Top of Door Section – Side View)
FIG. 10-C
FIG. 10-E
Required materials:
(2) 18” or 21” and (1) 27” or 50” length of angle iron
(4) 1/4’’x1’ bolts, (4) 1/4’ lock washers, (4) 1/4’’ nuts, and
(8) #14 x 5/8” sheet metal screws.
8'0'' up to 9'0'' Wide Doors
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
2"
48'' Long
Punched Angle
for Operator Draw
Bar Attachment
10'0'' up to 14'10'' Wide Doors
27'' or 50''
Long
27'' or 50''
Long
27'' or 50''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
18'' or 21''
Long
2"
Required materials:
(1) 18’’ or 21’ and (1) 48’ length of angle iron,
(6) ¼’’x1’ bolts, (6) ¼’ lock washers, (6) ¼’’ nuts, and
(4) #14 x 5/8” sheet metal screws.
FIG. 10-B
FIG. 10-D
14
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
Notch Cut
on Vertical Angle
(Drill holes in section or strut where required.)
P03-R02-0509
G01-R02-0905
STEP 11 – Assembling and Installing
the Track
Before assembling brackets to vertical track be sure to read
Step 11-1 and Step 11-2. Refer to illustration for placement of
brackets on track.
NOTE: Brackets may already be riveted in place. If additional
adjustment is required, the rivets can be drilled out and the
brackets can be reattached with track bolts and ange nuts
(available through the toll-free Consumer Services number, see
outside cover).
To avoid installation problems that could result in injury or
property damage, use only track provided with new door.
Step 11-1: Loosely fasten the track brackets to the vertical
track using one 1/4" x 5/8" track bolt and 1/4" ange nut as
shown with the head of the bolt inside the track. There are
two sizes of brackets for 7’ high doors, and three sizes for 8’
high doors. The shortest track brackets should be installed ten
inches from the bottom of the track with the ange facing the
at side of the track, one on the left and one on the right. The
next larger sized pair of brackets should be installed centered
on the track. If you have an 8’ high door, the remaining pair
of brackets should be installed ten inches from the top of the
vertical track. The at side of the track goes toward the wall.
(FIG. 11-A)
Step 11-2: Loosely attach the ag bracket to the top of the
track with two 1/4" x 5/8" track bolts and 1/4" ange nuts with
the head of the bolts in the track. Make sure bolts and nuts are
attached through the proper holes in ag bracket for your door
thickness. (FIG. 11-C)
(Refer to FIG. 11-B to determine proper bolt placement.)
NOTE: If additional adjustment is required, horizontal slots in
ag brackets can be used for attachment to vertical track.
Step 11-3: Place the track over the rollers on the door. Move
the track close to the door so that the rollers are all the way
into the hinges. Do not force the track too tightly or the door
will bind. This should leave about 1/2" between the edge of the
door and the track. Pilot holes of 3/16" are required at each
lag screw location before installing the lag screw. Lift track
about 1/2" from the oor and fasten the ag bracket and track
brackets to the jamb with 5/16" x 1-5/8" lag screws. The ag
bracket requires three screws, one each in the top, middle, and
bottom holes. Do this for both sides of the door. When the track
brackets and ag brackets are securely fastened to the jamb,
tighten the track bolts and ange nuts connecting the ag
brackets to the tracks. (FIG. 11-D)
NOTE: The tops of the vertical tracks must be level with
each other. Check this by measuring from the top of the door
sections to the top of the track on both sides. If they are not
equal, cut some material off the bottom of one track to lower it
or raise the other track.
Do not raise the vertical track beyond the bottom rollers
on the bottom section of door.
NOTE: Do not attach any brackets directly to drywall. All track
brackets, ag brackets, and spring brackets should only be
attached directly to wood bucks.
WARNING
FIG. 11-A
FIG. 11-B
FIG. 11-C
FIG. 11-D
1/4" Flange
Nut
1/4" x 5/8"
Track Bolt
Note: Use One
Track Bolt In Slot.
Top View
Left Side
Wall
Side
2" Thick Door
Use These
Two Holes
1-3/8" & 1-1/2"
Thick Door
Use These
Two Holes
Flag Bracket
Right Hand
Vertical
Track
Assembly
Longer
Track
Bracket
Shorter
Track
Bracket
Bottom
Finished Track Assembly
Top
Flag Bracket
Left Hand
Vertical Track
Assembly
15
1/4" x 5/8"
Track Bolt
1/4" Flange
Nut
G01-R01-0704
STEP 11 - Assembling and Installing the
Track (Continued)
NOTE: Pressure-treated lumber purchased after January 2004 is
treated with chemicals that have highly corrosive effects on metal
fasteners. The fasteners provided with your door are intended for
use with standard lumber (not pressure-treated) only. If you are
installing your door into an opening framed with pressure-treated
lumber purchased after January 2004, two items must be changed:
1) 5/16” x 1-5/8” lag screws with a minimum galvanization
equivalent to G185 must be purchased for this application, and
2) to prevent potential corrosion between lumber and track/spring
components, paint either the surface of the pressure-treated
lumber or those surfaces of the track and spring components that
come in contact with the pressure-treated lumber.
Step 11- 4: Fasten the horizontal angle to the horizontal (curved)
track with tw
o 1/4" x 5/8" track bolts and 1/4" ange nuts so that the
heads of the track bolts are on the inside of the track. On some
doors this angle may be 82" long and will require three additional
fasteners per side. If the angle has been preassembled, skip Step
11-4 and proceed with Step 11-5. (FIG. 11-E)
Step 11-5: Temporarily support the rear end of the track with a
rope from the trusses overhead in the garage or on a tall ladder.
(FIG. 11-F)
Step 11-6: Place the track over the roller in the top bracket. Attach
the curved end of the horizontal track to the ag bracket with two
1/4" x 5/8" track bolts and 1/4" ange nuts so that the heads of the
screws are on the inside of the track. The horizontal and vertical
track must join together to form a continuous channel for the
rollers. Attach the end of the horizontal angle to the top of the ag
bracket with a 3/8” x 3/4” carriage bolt and 3/8” hex nut. Use the
top set of slots for 15” radius track, the middle set of slots for 12”
radius track, and the bottom set of slots for Low Headroom track.
(FIG. 11-G)
Step 11-7: Rear track hangers need to be made at this time. Use
1-1/4" x 1-1/4" punched angle, 13 gauge or 3/32" steel. These are
not provided with the standard hardware. They are used to attach
the rear of the horizontal track to the ceiling joist.
Enough angle iron or punched angle should be purchased to make
two rear track hangers. These hangers must be strong enough
to hold the full weight of the door. Attach a bolt at least 1" long
through the end of each track to stop the door at the end of its
travel. (FIG. 11-H)
Sway braces must be used to prevent tracks from
spreading and allowing door to fall, which could cause
serious injury. Bolts placed in the end of each track
(FIG. 11-H) must be at least 1" long to prevent the top
section from exiting the track.
NOTE:
Rear track hangers should not be mounted any farther
than 6" from the end of horizontal track.
Step 11-8: Placement of rear track hangers is critical for the
door to operate properly. The rear track hangers should hold the
horizontal track level and square to the door. Squareness should
be measured by comparing two diagonal distances: 1) the distance
from the top left-hand corner of the door to the rear of the right-
hand horizontal track and 2) the distance from the top right-hand
corner of the door to the rear of the left-hand horizontal track. (FIG.
11-I, opposite page)
WARNING
FIG. 11-H
FIG. 11-G
FIG. 11-F
FIG. 11-E
Horizontal Angle
Horizontal Track
Horizontal
Track
Vertical
Track
Horizontal Angle Bracket
Flag Bracket
Sway Brace
Bolt Blocks
Door Travel
3/8" x 1"
Bolts & Nuts
(4 places)
16
Rope
Horizontal
Track
Horizontal
Angle
3/8" x 3/4"
Carriage
Bolt
G01-R02-0905
Slide
Top Roller
Bracket
Slide
Bolts
Step 11-8, Continued: Adjust the position of the tracks if
the squareness distances are not within 1/2" of each other.
Horizontal track can be out of level up to 1" from front jamb to
rear track hanger. (FIG. 11-I)
When the track is square and level with the opening, the track
hangers can be fastened permanently to the ceiling trusses.
Three 5/16" x 1-1/2" lag screws are recommended. Be sure
3/16" pilot holes are drilled before installing 5/16" lag screws.
The attachment must be strong enough to hold the weight of
the door.
Use adequate length screws to fasten rear track hangers
into trusses. Door may fall and cause serious injury if not
properly secured.
Step 11-9: With the track installed, the top door section can
now be properly adjusted. With the slide on the top bracket
loose, force the top of the door against the stop molding or
door jamb. Pull the roller towards you so it is tight against the
groove in the track and tighten the slide bolts. (FIG. 11-J)
At this time, remove the 3" nails that were used to hold
sections in place prior to installation of the track assembly.
(Refer back to FIG. 9-B.)
STEP 12 – Lock Installation (If Included)
Keyed Lock:
If your door has an exterior keyed lock, please complete the
installation of the lock at this time following the instructions
provided with your lock hardware. If your door has a slide bolt
lock, install according to the instructions below.
Slide Bolt:
The inside slide bolt is installed on the end stile of the second
section using (4) #14 x 5/8" hex head sheet metal screws (steel
doors) or (4) 1/4" x 1" lag screws (wood doors). (FIG. 12-A)
NOTE: 3/16" holes may have to be predrilled before installing
screws.
The slide bolt rests against the top of one of the rectangular
engaging slots in the vertical track. Proper alignment is easier
to achieve by using track as a guide.
NOTE: It may be necessary to knock out the slug in the vertical
track to open the slot for lock engagement. Remove slug by
striking with a hammer from the outside of the track.
IMPORTANT: If your door is going to be equipped with an
automatic garage door opener, make sure that the door is
always unlocked when the opener is being used. This will
avoid damage to the door.
STEP 13 – Pull Rope (Manually Operated
Doors Only)
To complete the door section installation, tie the pull rope
provided to the bottom roller shaft. (FIG. 13-A)
STEP 14 – Spring Installation
It is now time to install the spring. Proceed to springing
instructions that came with your spring hardware.
WARNING
Pull Rope
FIG. 13-A
FIG. 11-J
FIG. 11-I
FIG. 12-A
#14 x 5/8" Sheet Metal Screw or 1/4" x 1" Lag Screw
17
G01-R01-0704
STEP 15 – Attaching an Automatic Opener
IMPORTANT: To avoid damage to your door, you must
reinforce the top section of the door in order to provide a
mounting point for the opener to be attached. Refer to the
section of this manual titled Reinforcing the Top Section on
page 14 for speci c instructions. Failure to reinforce the door
as illustrated will void the warranty on your door.
To avoid risk of strangulation or personal injury to
children, if your door has a pull rope, you must remove
the pull down rope when you install an automatic garage
door opener.
IMPORTANT: When installing an automatic garage door
operator, make sure to follow manufacturer’s installation and
safety instructions carefully. Remove the pull down rope and
unlock or remove the lock. If attaching an operator bracket
to the wooden anchor pad, make sure the wood anchor pad
is free of cracks and splits and is rmly attached to the wall.
Always drill pilot holes before attaching lag screws.
The operator arm will usually be attached to the vertical
reinforcement member at roughly the same height as the top
roller of the door. Attach the opener arm to the reinforcement
as shown in Figures 15-B to 15-D. To prevent the top of the
door from bending, the opener rail should be mounted no less
than 2" and no greater than 5" from the face of the door with
the door in the open position (FIG. 15-A). Additionally, when
the door is closed, the portion of the operator arm attached to
the door should be at angle of approximately 60 degrees from
the vertical (FIG. 15-B).
WARNING
Opener Rail Mounting Distance
Ceiling
Opener Rail
Horizontal Track
Keep Clearance at 2"–5"
Top View
(assembled)
Opener
Arm
Lock These
Nuts Together
Securely
Leave
Clearance
Mounting
Surface Of
Door
Vertical Punched
Angle
Opener Arm
3/8" x
1-1/2"
Hex Bolt
3/8"
Hex Nut
Vertical
Punched
Angle
Horizontal
Punched
Angle
Opener Arm Attachment To Vertical Angle
FIG. 15-A
FIG. 15-D (Doors with Angle Iron Reinforcement
Bracket and Stile in Center of Door)
18
FIG. 15-B (Doors with supplied Reinforcement Bracket
and Stile in Center of Door)
60°
Clevis
Pin
FIG. 15-C (Doors with odd number of Panels)
Punched
Angle
Opener Arm Attachment To Horizontal Angle Or Strut
Horizontal Angle
Or Strut
Opener Arm
Supplemental
Bracket (Not Available
On All Doors)
Lock These Nuts
Together Securely
Punched
Angle
Horizontal
Angle
Or Strut
Front View (Assembled)
Opener Arm
Painting preparation: Clean surface first with a diluted
solution of Trisodium Phosphate. The recommended
concentration is 1/3 cup of powder to 1-1/2 to 2 gallons of
water. A cleaning pad (3M Synthetic steel wool GRAY not
green) should be used saturated with this cleaning solution.
Rub with even pressure to lightly scuff the surface while ap-
plying the cleaning solution over all surfaces to be painted.
A final wipe and rinse with clean water and sponge should
be done to remove any loose material. Change water often
to ensure clean rinse and allow to dry. Pre test your paint
on a small area (see paragraph Paint below). If the paint
shows signs of poor adherence, (tape test below) there may
be a problem with the paint or the surface preparation. DO
NOT PROCEED! A new paint or further preparation of the
surface is called for.
Alternate cleaning compounds: Areas of the country that
do not carry Trisodium Phosphate can use a biodegradable
cleaner with the cleaning pad above. Follow above
directions to rinse completely and pre test paint.
Painting: Your steel garage door can be painted with a
high quality 100% acrylic latex (flat, satin, or semigloss)
exterior grade paint. Before painting the door it must be free
of dirt, oil, caulk, waxes and mildew.
Do not use any type of oil based paint or Alkyd modified
acrylic latex paint. These paints will void the warranty of
your door.
C32-R0 -
1
15 yrs.
004 9
2009
48, 48B, 84A, 94, 4800, 4801, 4803, HDB4, T40F,
52, 52S, 54, 54S, 55, 55HB, 55S, 76V, 183, 186,
187, 190, 1000, 1001, 1100, 1500, 5200, 5201,
5203, 5500, 5501, 5503, HDS, HDSL, HDSF, T51S,
42, 42B, 46, 46B, 73, 75, 75L, 76, 4200, 4201,
4203, HDB, HDBF, HDBL, T50L, T50S, TM50S
T51F, T51L, T52L, T52S
T40L, TM40S, T41F, T41L, T41S, T42F, T42L, T42S
P/N 0137391 REV 00/
Glass, Plexiglass, Stained Look, Leaded
Look, Brilliance, and Studio Series Windows
Cleaning and Care Instructions
Clean with a mild solution of a dishwashing detergent
and a soft cloth. After cleaning, rinse thoroughly. DO
NOT use any ammoniated, abrasive, or solvent-based
cleaners of any kind.
Studio Series Windows Only:
Use a good grade of automotive paste wax and buff with a
soft cloth. Windows should be cleaned and waxed at least
once annually or more often based on the atmospheric
conditions where installed.
Caution: Use care when handling decorative windows to
avoid scraping or scratching the surface.
NOTE: Minor scratches or scuffs are not considered
1400 West Market Street
defects and will not be covered under the window warranty.
Troy, OH 45373 USA
0409
999
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Clopay 84A Installation guide

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Installation guide

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